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nervous about cutting my plexi...advice? (yes i have searched)
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Violineb:
There is but one more way to cut plastic :) (probably the best way) You get a table saw and a platic cutting blade and start sawing away. Watch your fingers ;) But seriously, table saws are very very useful things.
kahlid74:
Dremel 100%.

I tried scarring, and breaking and I messed up my finger pretty bad, was a stupid idiot.

Used the dremel and had it done in a snatch, no cracking or anything.
hulkster:
okay, so i use the flush trim bit, what size/type do i need to get?  and what do i drill the starter hole with...cordless drill with regular bit??  if not, what?  and if i use that panel bit thing, what size/type do i need for that?  ive never used any of these bits.  

crsdawg, you sound like it doesnt take very long to do this, and your panel turned out fine, so if you can, give me some product links or something at home depot or any other hardware store as to what to get.  thanks.
crsdawg:
"okay, so i use the flush trim bit, what size/type do i need to get?"

just about any flush trim bit should work. just make sure the blade is longer than your plex is thick, which is pretty much all of 'em.

"and what do i drill the starter hole with...cordless drill with regular bit?? "

i guess that would work as long as it's a good quality cordless(ie. 18v). personally i've never had to drill a starter hole because i use the panel pilot bit. you might get some cracking drilling the starter hole, but as long as they don't reach past the limits of the hole your ok. you could also use the sandwich method of drilling holes in plex to make these starter holes, but it seems like you'd be getting into a complex process tho.

"you sound like it doesnt take very long to do this"

once you've got the piece set up it goes by quick. just make sure you clamp down the plex so it doesn't move on you once your've started, this is key. you'll have to move a clamp from time to time to make way for the router, just make sure you always have at least one clamp on the panel at all times. it's also a good idea to use a piece of scrap wood under the clamp to keep it form marking the plastic. sometimes i clamp the top down, route a couple button holes then insert and tighten a couple buttons in them to keep the plex moving around. usually i don't do this, i route the outside, then switch to the panel pilot bit and do the buttons. again keeping the plex clamped and locked in place throughout the process is the most important thing, the routing is all most idiot proof.

"so if you can, give me some product links or something at home depot or any other hardware store as to what to get"

here's a link to the set i bought at harbor freight. they have it onsale for $35.00 right now, we've got a hf store here in town and i was able to get it for $28.00. 15 pcs, including a flush trim and a panel pilot.

harbor freight bit set

here's a pic of the bits i use if you'd like to look for them elsewhere. note i'm using a 1" flush trim instead of the one from the set.



one more tip, when your routing the button holes, make sure to clean off the little plastic slivers that tend to accumulate on the work surface after each hole is finished. if you don't, they will get stuck between the router and the plex and will eventually slice through the protective cover on the plex and can damage the surface. it's not a big deal, just route the hole, turn off the router, wipe off the slivers, move on to the next hole. some markings on the protecteve cover is inevitable, but as long as you keep the surface clean the underlying plex will be safe.
flampoo:
I used the same method Paige described for cutting the plexi on my most recent cab. I scored it a few times with an exacto knife, put it between two boards and it snapped off along the line. You have to be a bit cautious, but it works.
I would recommend giving yourself an extra 1/8" then just sand it down and it will fit perfectly. But TAKE YOUR TIME and SCORE IT WELL!
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